FORM NO. 3321–963 Wheel Horse 520xi Tractor 522xi Tractor Model No. 73542 – 9900001 & UP Model No. 73561 – 9900001 & UP Operator’s Manual IMPORTANT: Read this manual carefully. It contains information about your safety and the safety of others. Also become familiar with the controls and their proper use before you operate the product.
Introduction Thank you for purchasing a Toro product. All of us at Toro want you to be completely satisfied with your new product, so feel free to contact your local Authorized Service Dealer for help with service, genuine replacement parts, or other information you may require. Whenever you contact your Authorized Service Dealer or the factory, always know the model and serial numbers of your product.
Contents Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Safe Operating Practices . . . . . . . . . . . . . . Slope Chart . . . . . . . . . . . . . . . . . . . . . . . . . Safety and Instruction Decals . . . . . . . . . . Check Before Operating . . . . . . . . . . . . . . . . . . Opening the Hood . . . . . . . . . . . . . . . . . . . Closing the Hood . . . . . . . . . . . . . . . . . . . . Removing the Side Panels . . . . . . . . . . . . . Adding Fuel . . . . . . . . . . . . . . . .
Safety This machine meets or exceeds the B71.1–1996 specifications of the American National Standards Institute, in effect at the time of production. However, improper use or maintenance by the operator or owner can result in injury. To reduce the potential for injury, comply with these safety instructions and always pay attention to the safety alert symbol, which means CAUTION, WARNING, or DANGER—“personal safety instruction.” Failure to comply with the instruction may result in personal injury or death.
Safety 17. Use extra care when loading or unloading the machine onto a trailer or truck. DO NOT • 18. Do not touch equipment or attachment parts which may be hot from operation. Allow to cool before attempting to maintain, adjust or service. Do not operate machine on hillsides or slopes exceeding 15°. • Avoid turning on slopes. If you must turn, turn slowly and gradually downhill, if possible. Slope Operation • Do not mow near drop-offs, ditches, or embankments.
Safety Children Tragic accidents can occur if the operator is not alert to the presence of children. Children are often attracted to the machine and the mowing activity. Never assume that children will remain where you last saw them. The following requirements must be followed to prevent injury to children. 1. Keep children out of the mowing area and under the watchful care of another responsible adult. 2. Be alert and turn the machine off if children enter the area. 3.
Safety Slope Chart Read all safety instructions on pages 2–4.
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Safety Safety and Instruction Decals Safety decals and instructions are easily visible to the operator and are located near any area of potential danger. Replace any decal that is damaged or lost. ON DRIVE SHAFT COVER (Part No. 99–6090) ON FRONT OF SEAT BRACKET (Part No. 99–5339 ON FRONT OF SEAT BRACKET (Part No. 99–2985 ON BATTERY STRAP (Part No. 93–1265) ON ENGINE BULKHEAD (Part No. 98–5012) ON DRIVE SHAFT TUNNEL (Part No. 80–8760) (2) UNDER SIDE SHIELD (Part No.
Check Before Operating Each time before operating your tractor, check the following: • Fuel level • Engine oil level • Debris on the (3) air intake screens • Debris in the engine area • Debris on the rear transaxle cover • The safety interlock system • The brake 1 m–3314 Figure 1 1. Hood latch Some of these steps will require that you open the hood or remove the side panels on the tractor. Opening the Hood To open the hood: 1.
Check Before Operating Closing the Hood 2 1 The hood catch is located at the left hand corner of the grille. 1. Press rearward on the hood catch as you begin to lower the hood. 2. Push the hood down until the latch closes. 1 m–3318 Figure 3 2 1. Side panel latch 2. Open slot 2 Front of tractor Figure 2 1. Hood catch 2. Hood hinges Removing the Side Panels 1.
Check Before Operating Adding Fuel Use UNLEADED Regular Gasoline suitable for automotive use (85 pump octane minimum). Leaded regular gasoline may be used if unleaded regular is not available. POTENTIAL HAZARD • When fueling, under certain circumstances, a static charge can develop, igniting the gasoline. IMPORTANT: Never use methanol, gasoline containing methanol, or gasohol containing more than 10% ethanol because the fuel system could be damaged. Do not mix oil with gasoline.
Check Before Operating 2. 3. Clean around the fuel tank cap and remove the cap. Use a funnel and add fuel until the fuel level is 1/4 to 1/2 inch (6 mm to 13 mm) below the bottom of the filler neck. This space in the tank allows for expansion of the fuel. When filling the tank, make sure that the machine is on a level surface so that adequate air space is allowed. Do not fill the fuel tank completely. 1 2 Install the fuel tank cap securely. Wipe up any gasoline that may have spilled.
Check Before Operating 1. 2. Park the machine on a level surface, disengage the power take off (PTO), set the parking brake, lower the attachment lift, and turn the ignition key to “STOP” to stop the engine. Remove the ignition key. POTENTIAL HAZARD • Rotating air intake screen and drive shaft can cause injury. Check for debris on the (3) air intake screens (Fig. 6). Wipe away debris before each use and/or during use, if required.
Check Before Operating IMPORTANT: It is preferable to blow dirt out (Fig. 8), rather than washing it out. If water is used, keep it away from electrical items. Check the Safety Interlock System Always check the interlock system before operating the tractor. Instructions for checking the interlock system are found in the Operation section, page 14. Check the Brake Refer to Checking and Adjusting the Brake, page 34. m–3615 Figure 8 IMPORTANT: DO NOT HIGH–PRESSURE WASH.
Operation Think Safety First “Key Choice” Key Please carefully read all the safety instructions on pages 2–7. Knowing this information could help you, your family, pets or bystanders avoid injury. A turn and release key used for deactivating the “Operating–In–Reverse” interlock feature. Located on the seat bracket in front of and just below the seat (Fig. 11). Controls Become familiar with all the controls (Fig. 10) before you start the engine and operate the machine.
Operation Releasing the Parking Brake 1. Push down on the brake pedal (Fig. 10). The parking brake lever should release. 2. Release the brake pedal. Note: Starting and Stopping the Engine Allowing the engine to warm up before putting it under load will lengthen engine life. 2 Starting 1 1. Sit down on the seat. 3 2. Depress the brake pedal. m–3257 Note: 3. 4. The engine will not start unless you fully depress the brake pedal. 1. Throttle 2. Choke 3.
Operation Operating the Power Take Off (PTO) The Safety Interlock System Understanding the Safety Interlock System The power take–off (PTO) switch engages and disengages power to the electric clutch. If the ignition key is in the RUN or LIGHTS position and the power take off (PTO) is engaged, the PTO indicator light will be on. When this light is on, it is a reminder: the implement is being powered and the starter will not crank while the PTO is engaged.
Operation Before deactivating this feature, be sure there are no children present on or near the property where you are using the tractor, and that none are likely to appear while you are mowing or operating an attachment. Be extra observant after you have chosen to deactivate the interlock feature because the sound of the tractor’s engine might prevent you from being aware that a child or a bystander has entered the area where you are operating the tractor.
Operation 1 5. Fully depress the brake pedal, set the parking brake, push the PTO switch to OFF and start the engine. Pull the PTO switch to ON. Rise slightly from the seat; the engine should stop. 6. With the parking brake released, turn the ignition key to RUN without starting the engine. Pull the PTO switch to ON. You should hear an audible click indicating the PTO is activated and the PTO light will illuminate. Move the foot pedal to reverse.
Operation Gauges and Indicator Lights The indicator lights (Fig. 17) illuminate when certain controls are activated and when major malfunctions occur that need immediate attention. 1 2 3 4 7 5 8 Figure 17 Parking brake light PTO (power take off) light Battery light Operating–in–Reverse warning light Operating–in–Reverse Warning Light The Operating–in–Reverse warning light will illuminate whenever the “Key Choice” key is used to deactivate the operating–in–reverse interlock.
Operation Fuel Level Gauge This gauge shows the level of fuel remaining. POTENTIAL HAZARD • Excessive speed on slopes can result in rollover accidents or loss of control. Hour Meter The hour meter (Fig. 10) records the amount of time the engine has run. Use it to schedule regular maintenance. WHAT CAN HAPPEN • Rollover accidents or loss of control can result in serious injury or death. Driving Forward or Backward • Never shift into neutral while moving.
Operation Re–centering the Steering Wheel (Power Steering Models) 2 1 The power steering will not always return the steering wheel to the centered position. When this happens, the steering wheel will appear to be un–centered when the front wheels return to the straight–ahead position. 3 4 m–3258 Figure 18 1. Traction control pedal 2. Brake pedal 3. Forward 4.
Operation Attachment Power Lift Lowering Attachments The attachment power lift (Fig. 19) is used to raise and lower attachments. 1. Start the tractor. 2. Push the lift lever DOWN to lower the attachment (Fig. 20). 1 1 2 Figure 20 m–3258 1. Lift lever–Up 2. Lift lever–Down Figure 19 1. Attachment power lift Positioning the Seat Raising Attachments 1. Start the tractor. 2. Pull the lift lever UP to raise the attachment (Fig. 20). This will lift and hold the attachment in the raised position.
Operation Headlights and Taillights 2 1 The headlights and taillights are turned on by turning the ignition key to the LIGHTS position. They can be turned on even if the engine is not running. Remove the ignition key when leaving the machine unattended so that the headlights cannot be turned on and discharge the battery. m–3259 Figure 23 1. Tilt lever 2. Steering wheel 1 Using the Cruise Control m–3312 Figure 22 1. Lights The cruise control is a switch (Fig.
Operation 2. The cruise control has a “speed–up” feature: If you initially set it to any speed other than full speed, you can speed up with your foot on the traction pedal for as long as you wish. When you release the traction pedal, the pre–selected cruise speed resumes automatically. Disengaging the Cruise Control 1. While holding your foot steady on the traction control, move the cruise control switch (Fig. 10) to the “OFF” position. 2. This unlocks the traction control.
Operation To Push the Machine 1. Disengage the power take off (PTO) and turn the ignition key to “STOP” to stop the engine. 2. Move the High–Low range lever to the neutral position “N.” This allows the rear wheels to turn freely. 3. Place the lever back in High or Low after moving the machine, and set the parking brake.
Maintenance Service Interval Chart Service Operation Each Use 5 Hours 25 Hours 50 Hours 100 Hours 200 Hours Storage Service Engine Oil—check level X X Brake—check X X Safety System—check X X (3) Air Intake Screens—clean* X X Engine Area—clean* X X Rear Transaxle Cover—clean* X X Engine Oil—change Initial X X Engine Air Precleaner—clean* X X Tires—check pressure X X Transaxle—check oil level X Battery—check electrolyte level X X Transaxle—change oil Initial X X Tr
Maintenance POTENTIAL HAZARD • If you leave the key in the ignition switch, someone could start the engine. WHAT CAN HAPPEN • Accidental starting of the engine could seriously injure you or other bystanders. HOW TO AVOID THE HAZARD • Remove the key from the ignition switch and pull the wire(s) off the spark plug(s) before you do any maintenance. Also push the wire(s) aside so it does not accidentally contact the spark plug(s).
Maintenance Cleaning the Foam Element 1. Wash the foam element in liquid soap and warm water. When the element is clean, rinse it thoroughly. 2. Dry the element by squeezing it in a clean cloth. 3. Put one or two ounces of oil on the element (Fig. 26). Squeeze the element to distribute the oil. 1 2 IMPORTANT: Replace the foam element if it is torn or worn. m–3248 2 Figure 27 1. Paper element 2.
Maintenance Engine Oil Service Interval/Specification POTENTIAL HAZARD • Components under the hood will be hot if the tractor has been running. Change oil: • After the first 5 operating hours. • After every 100 operating hours. WHAT CAN HAPPEN • Touching hot components can cause burns. HOW TO AVOID THE HAZARD • Allow the tractor to cool before performing maintenance or touching components under the hood. Oil Type: Detergent oil (API service SG or SH) Crankcase Capacity: w/filter, 2.1 qts. (2.
Maintenance 3 2 1 1 1256 m–3262 Figure 28 1. Oil drain IMPORTANT: Overfilling the crankcase with oil may cause engine damage. Figure 29 1. Oil filter 2. Gasket 4. Install the replacement oil filter to the filter adapter. Turn the oil filter clockwise until the rubber gasket contacts the filter adapter, then tighten the filter an additional 1/2 turn (Fig. 29). 5. Fill the crankcase with the correct type of new oil; refer to Changing/Draining Oil, page 29.
Maintenance Spark Plugs 4. Remove the spark plug(s) and metal washer. 3 Service Interval/Specification 2 Change the spark plugs after every 200 operating hours. Make sure the air gap between the center and side electrodes is correct before installing the spark plugs. Use a spark plug wrench for removing and installing the spark plugs and a gapping tool/feeler gauge to check and adjust the air gap. 1 Type: Champion RC–12YC (or equivalent) Air Gap: 0.030” (0.76 mm) Removing the Spark Plug 1.
Maintenance 2 3 3. Connect a grease gun to the fitting. Pump grease into the fittings until grease begins to ooze out of the bearings. 4. Wipe up any excess grease. 1 0.030” (0.76 mm) Where to Add Grease m–3215 1. Lubricate the left–hand and right–hand spindles until grease begins to ooze out of the bearings (Fig. 32). 2. Lubricate the front axle pivot (Fig. 32). Figure 31 1. Center electrode insulator 2. Side electrode 3. Air gap (not to scale) Installing the Spark Plugs 1.
Maintenance 4. Lubricate the three grease fittings (Fig. 34) 1 m–3422 Figure 33 m–3419 1. Drive shaft maintenance cover Figure 34 ). POTENTIAL HAZARD • Rotating shaft or cooling fan can cause injury. 5. Replace and secure the cover. 6. Grease the fitting on the brake pedal (Fig. 35). WHAT CAN HAPPEN • Fingers, hands, feet, hair, etc. can get caught by shaft or fan. • Loose clothing can get caught by shaft.
Maintenance Manual Steering Models Put one pump of grease into the steering housing (from underneath the frame) (Fig. NO TAG) every 50 hours. 1 m–3319 Figure 37 1. Valve stem Brake m–3409 Figure 36 Always set the parking brake when you stop the machine or leave it unattended. Check the brake before each use. If the parking brake does not hold securely, an adjustment is required. Tire Pressure Service Interval/Specification Maintain the air pressure in the front and rear tires as specified.
Maintenance 3. Depress the brake pedal. There should be 2” (51 mm) of free travel (Fig. 38) before the brake begins to engage. IMPORTANT: With the parking brake released, the rear wheels must rotate freely when you push the tractor. If brake action and free wheel rotation cannot be achieved, contact your Authorized Service Dealer immediately. 2” Fuel Tank Draining The Fuel Tank m–3418 POTENTIAL HAZARD • In certain conditions gasoline is extremely flammable and highly explosive. Figure 38 4.
Maintenance should normally be left open, except for service on the fuel system or when the tractor is transported on a trailer. Fuel Filter Service Interval/Specification 1 m–3263 Replace the fuel filter after every 100 operating hours. Figure 40 1. Fuel shut-off valve Replacing the Fuel Filter 1. Disengage the power take off (PTO), set the parking brake, lower the attachment lift, and turn the ignition key to “STOP” to stop the engine. Remove the ignition key. 2.
Maintenance 7. Open the fuel shut-off valve at the fuel tank (Fig. 40 & 41). 8. Replace the side panels and close the hood. Front Wheel Toe-In Service Interval/Specification Maintaining correct front wheel toe–in is important for safety, Smart Turn Steering operation, and ease of use. If uneven tire wear, lawn scuffing, or hard steering develop, adjustment may be required. Check the toe-in after every 100 operating hours or once a year, whichever occurs first (Fig. 43).
Maintenance IMPORTANT: Make sure that the flat surface on the top of the front tie rod ends is parallel to the bottom of the steering arm (Fig. 45). 4. Clean around the transmission dipstick (Fig. 46) so dirt cannot fall into the filler hole and damage the transaxle. 1 2 2 1 m–3583 m–3260 Figure 45 View from front of tractor looking at the tie rod 1. This 4. Figure 46 1. Transmission dipstick and filler tube 2. Not this Recheck the toe–in; refer to Measuring Toe–In, page 37. 5.
Maintenance Changing Transaxle Oil Replace the transaxle fluid at 50 hours initially, then every 200 hours thereafter. Fluid Type: SAE 10W–30 Detergent oil (API service SG, SH or above) Transaxle Capacity—Power Steering Models: Total system capacity: 7.0 qts. Approximate refill capacity: 4.5 qts. 1 m–3322 Transaxle Capacity–Manual Steering Models: Figure 48 Total system capacity: 6.0 qts. Approximate refill capacity: 4.5 qts. 1. Warm up the transaxle oil by driving the tractor. 2.
Maintenance Fuses Service Interval/Specification 3 The electrical system is protected by fuses. They require no maintenance. However, if a fuse blows, check the component and circuit for a malfunction or short. To replace a fuse, pull it out of the fuse box (Fig. 50). 2 1 1256 Figure 49 1. Transaxle filter 2. Gasket 3. Adapter 1 2 3 4. 5. Install the replacement transaxle filter to the filter adapter.
Maintenance Headlights Installing the Bulb Specification: Bulb # 1156 Automotive Type 1. Removing the Bulb 1. The bulb has metal pins on the side of its base. Align the pins with the slots in the bulb holder and insert the base into the holder (Fig. 52). Push and rotate the bulb clockwise until it stops. Disengage the power take off (PTO), set the parking brake, lower the attachment lift, and turn the ignition key to “STOP” to stop the engine. Remove the ignition key. 2. Open the hood.
Maintenance Taillights Battery Bulb: GE 194 Service Interval/Specification Removing the Bulb Check the electrolyte level in the battery every 25 hours. Always keep the battery clean and fully charged. Use a paper towel to clean the battery case. If the battery terminals are corroded, clean them with a solution of four parts water and one part baking soda. Apply a light coating of grease to the battery terminals to prevent corrosion. 1.
Maintenance Removing the Battery 1. Disengage the power take off (PTO), set the parking brake, lower the attachment lift, and turn the ignition key to “STOP” to stop the engine. Remove the ignition key. 2. Remove the front grille by pulling it outward toward you. 3. Remove the battery shield (Fig. 55). 1 IMPORTANT: Always disconnect the negative (black) cable first. Figure 54 1. Lower part of the battery cell tube 4. Disconnect the negative (black) ground cable from the battery post (Fig. 55).
Maintenance 6 1 3 POTENTIAL HAZARD • Either the battery terminals or metal tools could short against metal tractor components. • Incorrect battery cable routing could damage the cables. 5 2 8 WHAT CAN HAPPEN • Sparks can cause the battery gasses to explode. • Damaged cables could short against metal tractor components and cause sparks. HOW TO AVOID THE HAZARD • When removing or installing the battery, do not allow the battery terminals to touch any metal parts of the tractor (below the headlights).
Maintenance Charging the Battery IMPORTANT: Always keep the battery fully charged (1.260 specific gravity). This is especially important to prevent battery damage when the temperature is below 32°F (0°C). 1. Remove the battery from the chassis; refer to Removing the Battery, page 43. 2. Check the electrolyte level; refer to Checking the Electrolyte Level, page 42, steps 2–5. 3. Remove the cell covers from the battery and connect a 3– to 4–amp battery charger to the battery posts.
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Maintenance Cleaning and Storage 1. 2. Disengage the power take off (PTO), set the parking brake, and turn the ignition key to “STOP” to stop the engine. Remove the ignition and “Key Choice” keys. 3. Check the brake; refer to Brake, page 34. 4. Service the air cleaner; refer to Air Cleaner, page 27. 5. Grease the chassis; refer to Greasing and Lubrication, page 32. 6. Change the crankcase oil; refer to Engine Oil, page 29.
Troubleshooting PROBLEM The starter does not crank. The engine cranks, but will not start. 48 POSSIBLE CAUSES CORRECTIVE ACTION 1. The PTO is ON. 1. Move the PTO to OFF. 2. The brake is not depressed or the parking brake is not on. 2. Set the parking brake. 3. The operator is not seated. 3. Sit on the seat. 4. The electrical connections are corroded or loose. 4. Check the electrical connections for good contact. 5. A fuse is blown or loose. 5. Correct or replace fuse. 6.
Troubleshooting PROBLEM The engine starts, but does not keep eep running u g The engine runs, but knocks or misses. sses The engine will not idle. POSSIBLE CAUSES CORRECTIVE ACTION 1. Misadjusted or faulty choke or throttle control cable. 1. Contact your Authorized Service Dealer. 2. The fuel tank vent is restricted. 2. Contact your Authorized Service Dealer. 3. Dirt or water in the fuel system. 3. Drain and flush the fuel system; add fresh fuel. 4. The fuel filter is clogged. 4.
Troubleshooting PROBLEM The engine overheats. POSSIBLE CAUSES CORRECTIVE ACTION 1. The crankcase oil level is incorrect. 1. Fill or drain to the full mark. 2. The fuel mixture is lean. 2. Contact your Authorized Service Dealer. 3. Excessive loading. 3. Reduce load; use lower ground speed. 4. (3) air intake screens are dirty. 4. Clean with every use. 5. The cooling fins and air passages under the engine blower housing and/or the rotating air intake screen are plugged. 5.
Troubleshooting PROBLEM The tractor will not operate in either direction. e t e d ect o POSSIBLE CAUSES CORRECTIVE ACTION 1. The High–Low range lever is in “N.” 1. Move the High–Low range lever to “L” or “H.” 2. The transmission oil is low. 2. Fill to the full “F” mark on the transmission oil dipstick when the transmission is cold. 3. The transmission is faulty. 3. Contact your Authorized Service Dealer. 4. The control linkage needs adjustment or replacement. 4.
Troubleshooting PROBLEM Abnormal vibration or noise. PTO (cutter deck) belt comes off of pulleys, slips, or fails. 52 POSSIBLE CAUSES CORRECTIVE ACTION 1. The engine mounting bolts are loose. 1. Tighten the engine mounting bolts. 2. The idler pulley or cutter deck blade is loose. 2. Tighten the appropriate pulley. 3. The transaxle cooling fan is loose. 3. Contact your Authorized Service Dealer. 4. There is a problem with the electric clutch 4. Contact your Authorized Service Dealer. 1.
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Consumer Riding Products THE TORO TOTAL COVERAGE GUARANTEE A Full TwoĆYear Warranty (Limited Warranty For Commercial Use) What Is Covered By This Express Warranty? The Toro Company promises to repair any TORO Product used for normal residential purposes* if defective in materials or workmanship for a period of two years from the date of purchase with the following exceptions: D Batteries are warranted for one year This warranty covers the cost of parts and labor as well as transportation within a 15 mil
